DE102004047901A1 - Charge intercooler for a motor vehicle comprises a heat exchanger block with tubes through which charge air flows and part of which can be sealed, and air boxes connected to the tubes and having an air inlet and an air outlet - Google Patents

Abstract

Charge intercooler for a motor vehicle comprises a heat exchanger block with tubes (3) through which charge air flows, and air boxes (1) connected to the tubes and having an air inlet and an air outlet. A part of the tube can be sealed. An independent claim is also included for an alternative charge intercooler. Preferred Features: A part of the tube can be sealed by a sealing element arranged in the air box.

Description

The The invention relates to a charge air cooler of a motor vehicle according to the preamble of claim 1.

Intercoolers for motor vehicles are known; they serve to cool the combustion air compressed by a compressor or turbocharger in order to obtain a better filling of the cylinders, ie a better delivery rate. For motor vehicles are usually air-cooled intercoolers used, as z. B. by the DE-A 198 57 435 or the DE-A 199 62 861 the applicant were known. The intercooler usually has a heat exchanger block or a so-called network, which consists of tubes, usually flat or rectangular tubes, between which corrugated fins are arranged to increase the heat exchange surface. The tubes are held with their tube ends in tube sheets. Tubes, ribs and tubesheets are made of aluminum materials and are soldered together. On the tubesheets, so-called air boxes are placed, which act as a distributor or collecting tanks for the charge air. These air boxes may consist of an aluminum material, but also of plastic. In certain applications, liquid-cooled intercoolers are in use, the coolant of the cooling circuit of the internal combustion engine is used to cool the charge air. The intercooler of a motor vehicle is usually mounted in front of or behind the coolant radiator and often part of a cooling module, which is arranged in the front engine compartment of the motor vehicle.

at Car diesel engines are more due to the formation of soot in the exhaust and more particle filters used at specific intervals need to be regenerated. For certain types of particulate filters, regeneration (soot burn-up) is one Raising the exhaust gas temperature required, which in cold outside temperatures often unavailable. The invention assumes that with Help a reduced cooling the charge air under certain circumstances the increased Exhaust gas temperature for a Russabbrand is reachable. Also, especially at cold ambient temperatures an accelerated warm-up of the vehicle engine possible.

It is therefore an object of the present invention, a charge air cooler of to equip the aforementioned type with funds, if necessary a reduced cooling the charge air opposite the standard cooling of the Allow charge air.

These The object is solved by the features of claim 1. According to the invention, it is provided that for the case of reduced cooling a certain number of tubes of the intercooler is shut off, d. H. that the charge air flow is prevented by these pipes. Accordingly, for example Only 10 percent to 30 percent of the pipes flowed through by charge air, which to a lower cooling the exiting charge air leads. Thus, the advantage is achieved that one - even with unfavorable External conditions, z. B. low outside temperatures - an increased exhaust gas temperature gets the for a filter regeneration or Rußabbrand is required.

To an advantageous embodiment of the invention, the pipes, which does not flow through charge air are to be closed by a shut-off, which preferably in one of the air boxes, i.e. is arranged on the inlet or outlet side. An advantage here is that the obturator is integrated in the intercooler and not must be mounted separately. In addition to the ambient temperature are also the boost pressure, the charge air temperature, the charge air mass flow, the engine speed, the engine load, the operating point of the compressor, the driving speed or the temperature of the coolant individually or in any combination possible control variables for closing or for the Shut-off possible. The actuator is preferably made of metal, in particular aluminum, or made of plastic.

Shut-off valves for closing a number of pipes are known in exhaust gas heat exchangers. For example, was by the DE-A 199 62 863 the applicant knows an exhaust gas heat exchanger for an additional exhaust gas heater, wherein the exhaust gas is directed by means of a "switch" either through the exhaust gas heat exchanger or by a bypass.This switch is designed as a flexible actuator Other forms of exhaust valves or shutters were by the DE-A 102 03 003 also known, wherein this exhaust gas heat exchanger has an integrated bypass with a switch and the exhaust gas flow is passed either through all the tubes of the exhaust gas heat exchanger or through the bypass. Finally, by the DE-C 31 03 198 and the DE-C 32 18 984 Exhaust gas heat exchanger known for the heating of motor vehicles, wherein the exhaust gas stream is directed by means disposed in the heat exchanger flaps through different flow channels. This is intended to adapt the heating power to different exhaust gas flows.

According to an advantageous embodiment of the invention, the flap is designed as a preferably rectangular flap with a lateral pivot axis, which in the immediate area of Roh arranged and thus covers a part of the pipe ends or closes. The flap can be relatively easily arranged and fixed in the air box. When the door is open, ie not closed pipes created by the installation of the flap on the wall of the charge air box no additional pressure drop for the standard intercooler, in which all tubes are flowed through by the charge air.

According to one embodiment the flap has at least one recess for one or more non-closable tubes on. This way, one or more pipes remain in the desired position Positions open.

To a further advantageous embodiment of the invention is the Air box divided by a transverse partition into two chambers, each chamber being assigned a portion of the total number of charge air ducts is. Preferably, both chambers are in a funnel-shaped channel (Bottleneck) merged, where the obturator is located. The latter closes one the two chambers, preferably those with a higher number of tubes, thereby the charge air flow is prevented by these pipes. The advantage of this solution is in that the obturator is smaller than the cross-sectional area to be covered Tubes executed can be, which also the restoring forces for the adjustment of the obturator become smaller. Preferably, this narrowed channel cross-section trained round and the flap in its cross section accordingly customized.

According to one another embodiment the obturator is designed as a rotary valve. For example becomes a wall, in particular along a cylinder circumference is arranged to turn an axis and locked in one position some pipes while the pipes are open in another position of the rotary valve.

According to one embodiment is the obturator as a semicircular. Flap with lateral or central Swivel axis formed. It is possible that the Flap when opening a wall, in particular a partition wall applies. This is a reduction a caused by the flap flow resistance possible.

According to one further embodiment the obturator sections for the cover of individual tubes, so that these tubes are lockable. The cover sections are preferably displaceable together and / or rotatably mounted. In particular, the cover sections are between a position covering the pipe ends and one opposite the Pipe axes offset position displaced. In another example the cover sections are mounted on a common axis, where the axis is in the longitudinal direction a row of tubes extends. It is also possible individual cover sections at the same time from the mouth area to unscrew and slide single tubes.

According to one embodiment some pipes are complete closable. According to further embodiments are individual tubes, in particular all tubes, only partially closable. In addition to the complete close of some pipes it is also possible to close all pipes, in which case at least some of the individual tubes are only partially closed be, so that the intercooler Charge air can flow through it at any time.

The The object of the invention is further characterized by the features of claim 20 solved, which is a parallel solution to claim 1 represents. The intercooler is U-shaped, d. H. perfused twice and on the one hand has a charge air box with an inlet and outlet opening and a partition on the other hand, a deflection box. In the Partition is a shut-off device, preferably a round pivoting flap arranged. This also contributes to the advantage of reduced charge air cooling open Flap achieved because a considerable Proportion of inflowing Charge air directly, d. H. Shelf into the outlet. The advantage of this solution is, above all, that the obturator in the partition wall structurally relatively simple to master and therefore connected only with little additional effort is.

embodiments The invention are illustrated in the drawings and will be described in more detail below. Show it

1 . 1a A first embodiment of the invention with a pivoting flap,

2 a second embodiment with a round flap,

3 Another embodiment with a round flap and a partition in the air box,

4 a modified embodiment with a partition and a recessed flap,

5 a perspective view of the design with partition and semicircular flap,

6 an embodiment with a Flap in a partition,

7a C an embodiment with a rotary valve,

8a FIG. 1b shows an embodiment with a plurality of covering sections, FIG.

9 an embodiment with a roller blind and

10 a further embodiment with Abdeckabschnitten.

1 shows a schematic representation of an outlet-side air box 1 a charge air cooler, not shown in full, having a further, not shown inlet side air box. The air box 1 , on which an unillustrated air outlet is arranged, is on a tubesheet 2 put on and connected to this. The tube sheet 2 is preferably made of an aluminum material and has - perpendicular to the plane - a number of unillustrated passages, in which pipes 3 with their pipe ends 3a used and soldered. The air box 1 can be made of a plastic or aluminum material. Accordingly, the connection with the metallic tube sheet 2 a mechanical flare or a cohesive, z. B. soldered connection. The pipes 3 have a rectangular cross-section, the long side with the depth T is parallel to the plane of the drawing. Between the pipes 3 not shown corrugated fins are arranged with the pipes 3 form a heat exchanger block or a so-called network, which is flowed through by ambient air in the direction of an arrow L. Such a charge air cooler is usually arranged in the front region of an engine compartment, not shown, of a motor vehicle, usually together with other heat exchangers, such. B. a coolant cooler.

at other embodiments is the intercooler near arranged the vehicle engine.

In the charge air box 1 is a hinged flap 4 arranged, the pivot axis 5 next to the pipe end 3a and in the area of the tube bottom 2 located. The flap 4 is shown in the open position, ie in approximately parallel position to a side wall 1a of the air box 1 , To the or individual pipes 3 to shut up, the flap 4 pivoted 90 degrees so that they are on the pipe end 3a comes to rest and closes this. The operation of the flap 4 and their storage in the air box 1 are not shown and correspond to the above-mentioned prior art. The flow through the charge air pipes 3 takes place in the direction of the arrow LL, ie the flap 4 is opened with the flow pressure and closed against the flow pressure. An unillustrated arrangement of the flap in the charge air inlet side air box is also possible. The arrow LL would then have to point in the opposite direction.

1a shows an enlarged view of the flap 1 in relation to the pipes 3.1 . 3.2 . 3.3 . 3.N-1 and 3.N forming a series R Slightly above the pipe ends is the flap axis 5 the flap 4 arranged and stored in a manner not shown. The flap 4 is rectangular in shape and has a height H and a width B. The height H corresponds at least to the depth T (cf. 1 ) of the pipes 3 so that the pipe cross-sections are covered with the flap closed. The width B is in 1a so chosen that the pipes 3.2 to 3.N-1 with the flap closed 4 are covered and only the two outer tubes 3.1 and 3.N stay open and be flowed through by the charge air.

at not shown embodiments remains only one tube or remain several, in particular more than two tubes open. These tubes are at one or both edges of a respective row of tubes arranged. It can but also tubes in the middle of a row of tubes remain open. To do this several flaps or preferably a flap with recesses used wherein the recesses are associated with the tubes that remain open should.

2 shows a further embodiment of the invention with an outlet-side air box 6 which is in one plane 6a is connected to a tube bottom, not shown, or a heat exchanger block with opening into the tube plate tubes. At the level 6a opposite side of the air box 6 is a charge air outlet 6b arranged. Inside the charge air box 6 is an angled partition 7 arranged, which consist of three areas 7a . 7b . 7c composed and the air box 6 in two chambers, namely a first closable chamber 8th and a second passage chamber 9 divided. Between the partition walls 7b . 7c is a round swing flap 10 arranged, whose scope 10a is shown in dashed lines in Durchlassstellung. The closed position is indicated by the solid line 10 shown. In the lockable chamber 8th open a first number of pipes, not shown, and in the passage chamber 9 open a second number of tubes, not shown, which - is smaller than the first number, ie approximately in the ratio of 1: 2 to 1: 5 - according to the graphic representation.

With closed chamber 8th Thus, only the tubes are flowed through by the charge air into the passage chamber 9 lead. Accordingly is the cooling of the charge air, over the outlet 6b the intercooler leaves less than when the flap 10 would be open and all the pipes of the intercooler would flow through.

3 shows a modified embodiment of the invention with an air box 11 that with a plane 11a Connected to a heat exchanger block, not shown, of a charge air cooler, not shown. The air box 11 has an outlet nozzle 11b and a dashed partition shown 12 on, which is different from the dividing plane 11a to the outlet nozzle 11b extends. The partition 12 shares the air box 11 into a first larger chamber 13 and a second smaller chamber 14 , a so-called passage chamber, on. The chamber 13 is in the area of the outlet nozzle 11b through a round pivoting flap 15 lockable, their scope 15a dashed.

With the flap closed 15 , which is the solid line 15 corresponds, is the chamber 13 , in which open a first number of pipes, not shown, closed, ie the flow through these pipes is interrupted. The in the passage chamber 14 opening pipes, not shown, however, are open and are flowed through by charge air, which is thus cooled. Overall, with the flap closed 15 the charge air flowing through the intercooler cooled less than with open flap 15 (Standard cooling).

4 shows a modification of the embodiment according to 3 with the air box 11 and the partition 12 and the outlet nozzle 11b , which is a circular, by a dashed line 11c has folded in the plane of the cross section. The cross section of the outlet nozzle 11b is through a section 12a the partition 12 in two partial sections 13a . 14a divided, with the partial cross section 13a who with the chamber 13 Corresponds, by a round pivoting flap 16 is closable. The swing flap 16 appears in the drawing in its closed position as a solid line 16 and in its open position as a dashed line 11c passing through the partition wall section 12a is cut off, so that the full circle 11c (dashed line) in the area of the partial cross-section 14a is omitted. The partial cross section 14a is thus always open. A perspective view of this embodiment is shown in the next figure.

5 shows the embodiment according to 4 in a perspective view, wherein the same reference numerals are used for the same parts. The charge air box 11 closes with the plane 11a to a tube bottom, not shown, which tube ends 17a of rectangular tubes 17 receives. Between the rectangular tubes 17 (Tubes with approximately rectangular cross-section) are corrugated ribs 18 arranged. The air box 11 covers the entire not fully shown tubesheet and is through the transverse partition wall 12 in the chambers 13 and 14 divided.

The air box 11 narrows like a funnel to an inlet nozzle (outlet nozzle) 11b which has a circular cross-section 11c having. The circular cross section 11c is through the partition 12 in the partial cross section 13a (dark) and the partial cross-section 14a divided. In partial cross-section 13a is the semicircular swing flap 16 arranged around either a folding axis 16a or alternatively about a pivot axis 16b is pivotable. In both cases the swing flap closes or opens 16 the partial cross-section 13a , whereby the charge air flow through the chamber 13 and the pipes connected to it is prevented. The flow through the two - in the drawing below - tubes 17 entering the chamber 14 on the other hand, it is not interrupted. These flow channels always remain open. The control of the flap 16 is not shown; it takes place from the outside, z. B. in a manner as explained in the above-mentioned prior art for exhaust gas heat exchanger.

6 shows a further embodiment of the invention for a charge air cooler 20 which is a heat exchanger block 21 , an upper air box 22 and a lower air box 23 , Having a so-called deflection box. The upper air box 22 has an inlet nozzle 24 and an outlet 25 and a partition disposed between the two 26 on top of the air box 22 in an inlet and an outlet chamber 24a . 25a Splits. The intercooler 20 is thus U-shaped, ie flows according to the arrows P in two directions, from top to bottom and from bottom to top.

In the partition 26 is a round swing flap 27 arranged, whose outline 27a as a broken line in the drawing plane is folded and marked their open position. The swing flap 27 , which can be controlled from the outside in a manner not shown, thus gives a circular cross-section 27a in the partition 26 free or close it. With the flap closed 27 There is a standard intercooler, ie 100 percent. With the flap open 27 does not flow the entire charge air according to the arrows P through the block 21 but only a partial flow. The other partial flow goes directly from the inlet nozzle 24 through the opening in the partition 26 to the outlet nozzle 25 , This results in only a reduced cooling of the charge air, ie from the outlet nozzle 25 escaping charge air has a higher charge air temperature than standard cooling.

7a -C each show a collection box 30 a charge air cooler, in which the side facing a pipe-fin network of the intercooler side is not shown for illustrative purposes. A rotary valve 31 is in 7a before installation in the collecting box, in 7b in a first position for partial flow through the intercooler and in 7c shown in a second position for complete flow through the intercooler.

The rotary valve 31 limited in the installed state, a cylindrical partial volume of the collecting tank 30 , Part of the Zylindermantelfäche is thereby through the wall 44 of the rotary valve 31 Covered, a remaining part of the cylinder surface remains free. A wave 43 in extension of the cylinder axis of the cylindrical partial volume serves as a point of attack for a rotation of the rotary valve 31 around the cylinder axis, wherein the rotation is driven, for example, by an actuator such as an electric stepping motor, a vacuum or overpressure can or the like. By such a rotation is a targeted displacement of the wall 44 possible along the cylindrical surface.

A round opening 32 with a border 36 in the collection box 30 forms the in the 7a -C overhead face of the cylinder volume and is used to introduce the rotary valve 31 in the collection box 30 , An end wall 33 of the rotary valve 31 covers after its installation the opening 32 from and seals over the sealing surface 34 and the inner surface 35 of the edge 36 the opening 32 the interior of the collecting tank 30 from the environment.

A round opening 37 in the collection box 30 forms the in the 7a -C bottom face of the cylinder volume and serves the inflow of charge air to be cooled. Because of this, the opening remains 37 not open and not by the rotary valve 31 covered.

The collection box 30 furthermore has a partition wall 38 on that the inside of the collecting tank 30 in a first compartment 39 and a second sub-chamber 40 divides. The first compartment 39 is fluidly connected to pipes of a first pipe group of the pipe-finned network, not shown, while the second partial chamber 40 is fluidly connected to pipes of a second pipe group of the pipe-fin network.

In addition, the collection box points 30 reinforcing ribs 41 to stabilize its geometry during operation of the intercooler and a plant 42 for connection to a tube sheet, the tube sheet receiving the tube ends of the tube and fin mesh.

In a normal operation of the intercooler ( 7c ) Charge air flows through the opening 37 in the cylindrical, by the rotary valve 31 limited partial volume of the collecting tank 30 into and on its subchambers 39 and 40 and distributed from there to the corresponding pipe groups of the pipe-rib network. The ratio of the number of tubes of the first tube group to the number of tubes of the second tube group corresponds approximately to the cross-sectional ratio of the sub-chambers 39 and 40 and is preferably 1: 1 to 1:10, more preferably 1: 2 to 1: 5.

In an operation of the intercooler with reduced cooling of the charge air ( 7b ), however, the charge air flows only in the first sub-chamber 39 because the second compartment 40 through the wall 44 of the rotary valve 31 is locked. The rotary valve is used for this purpose with the help of the shaft 43 from the position in 7c in the position in 7b turned.

It Therefore, only the tubes of the first tube group and not the tubes the second tube group charged with charge air, so that the the charge air dischargeable heat output across from is lowered to normal operation. The degree of this reduction in heat output results from the ratio the number of tubes of the first tube group to the total number of tubes Intercooler. The proportion of closed tubes is preferably 50% to 90%, more preferably 70% to 80% of the total number of tubes.

8a -B show a collection box 50 a charge air cooler schematically in cross section. The collection box 50 has a housing 54 and a tube sheet 51 with openings for receiving the ends of pipes 52 on, wherein for an enlargement of the heat-transferring surface corrugated fins 53 between the pipes 52 are arranged.

On a wave 55 are cover sections 56 attached to the ends of some of the pipes 52 are arranged. The wave 55 is on one side of the collecting tank 50 rotatably mounted and on the other side through an opening 57 from the collection box 50 led out. The shaft is driven 55 in turn, for example, by an actuator such as an electric stepper motor, a vacuum or overpressure.

In a first position ( 8a ) extend the cover sections 56 parallel to the pipes 52 , so that charge air into the collection box 50 enters, at the cover sections 56 over in all tubes 52 can flow in. By rotation of the shaft 55 by 90 °, for example, a second position ( 8b ), in which the cover sections 56 some of the pipes 52 Cover and thus block for the charge air. It will therefore only the rest (Uncovered) tubes charged with charge air, so that the dischargeable from the charge air heat output compared to the normal operation is lowered.

In a similar, not shown embodiment cover portions are slidably mounted, in particular via one of the shaft 55 similar wave, which is self-displaced stored. From a position covering the tubes, the cover sections are displaceable, in particular in the longitudinal direction of the tubes or perpendicular thereto, into a position releasing the tubes.

9 shows a similarly constructed collection box 60 also in a schematic cross section. Unlike the in 8th embodiment shown are in 9 cover sections 61 not mounted on a rotatably mounted shaft, but on a sliding frame, a belt, a chain or the like. The frame, the band or the chain are, for example via a further chain or directly, on a roll 62 attached so that over a rotation of the roller 62 a shift of the cover sections 61 can be reached between a first and a second position.

In the first position are the pipe ends 63 through the cover sections 61 covered and in the second position, the cover sections 61 each next to the pipe ends 63 lie so that in the second position, all tubes are acted upon and the cooling capacity of the heat exchanger is lowered in the first position relative to the second position. A partition 64 serves on the one hand a separation of the covered pipe ends 63 from the other pipe ends and on the other hand, a storage of the frame, the band or the chain for the cover sections 61 ,

10 shows another collection box 70 in a schematic cross section. cover sections 71 . 72 are designed as double-leaf flaps, which in a first position ( 71 ) an admission of all pipes 73 in a second position ( 72 ), however, a part of the tubes 73 close. The two wings of each cover sections 71 . 72 are moved toward each other for opening, but moved away from each other for locking.

The The invention has been explained with reference to examples of a motor vehicle intercooler. It will However, it should be noted that the invention also applies to others Purposes is suitable.

Claims (21)

Charge air cooler of a motor vehicle, consisting of a heat exchanger block with pipes through which charge air can flow ( 3 ) and out with the pipes ( 3 ) associated air boxes ( 1 ), which have a charge air inlet and a charge air outlet, characterized in that a part of the tubes is closable. Intercooler according to claim 1, characterized in that the part of the tubes by a shut-off ( 4 . 10 . 15 . 16 ) is closable. Intercooler according to claim 2, characterized in that the obturator ( 4 . 10 . 15 . 16 ) in the charge air box ( 1 . 6 . 11 ) is arranged. Intercooler according to claim 2 or 3, characterized in that the obturator ( 15 . 16 ) is arranged in the region of the charge air inlet. Intercooler according to claim 2 or 3, characterized in that the obturator ( 10 ) in the region of the charge air outlet ( 6b ) is arranged. Intercooler according to one of claims 2 to 5, characterized in that the obturator as a pivotable flap ( 4 ) with a laterally arranged Schvvenkachse ( 5 ) is trained. Intercooler according to claim 6, characterized in that the tubes ( 3 ) form a row R and pipe ends ( 3a ) in a tube sheet ( 5 ) of the air box ( 1 ) and that the pivot axis ( 5 ) in the direction of the tube row R and next to the tube ends ( 3a ) in the region of the tube bottom ( 5 ) is arranged. Intercooler according to claim 7, characterized in that the flap ( 4 ) is formed in particular approximately rectangular and in closed position on the pipe ends ( 3a ) rests. Intercooler according to claim 8, characterized in that the flap at least a recess for one or more non-closable tubes having. Intercooler according to one of claims 2 to 5, characterized in that in the air box ( 6 . 11 ) a partition wall ( 7 . 12 ) is arranged, which the air box in two chambers ( 8th . 9 ; 13 . 14 ) with two flow cross sections ( 13a . 14a ) and that a flow cross-section ( 13a ) through the obturator ( 10 . 15 . 16 ) is closable. Intercooler according to claim 10, characterized in that the obturator is designed as a rotary valve. Intercooler according to claim 10 or 11, since characterized in that the chambers ( 13 . 14 ) and the partition ( 12 ) funnel-shaped into a connecting piece ( 11b ), in which the obturator ( 15 . 16 ) is arranged. Intercooler according to claim 12, characterized in that the obturator ( 15 ) as a round flap with a central pivot axis ( 15 ) is trained. Intercooler according to claim 12, characterized in that the obturator as a round, partially recessed flap ( 16 ) with lateral ( 16a ) or centered ( 16b ) Pivot axis is formed. Intercooler according to claim 12, characterized in that the obturator designed as a semicircular flap with lateral or central pivot axis is. Intercooler according to one of the claims 2 to 5, characterized in that the obturator cover sections for individual Having tubes that mounted together displaceable and / or rotatable are. Intercooler according to one of the preceding claims, characterized that some pipes completely lockable are. Intercooler according to one of the preceding claims, characterized that some pipes are only partially closable. Intercooler according to one of the preceding claims, characterized that all tubes are at least partially closed. Intercooler ( 20 ) of a motor vehicle, consisting of a heat exchanger block ( 21 ) with tubes through which charge air can flow and with air boxes connected to the tubes ( 22 . 23 ) which has a charge air inlet ( 24 ) and a charge air outlet ( 25 ), characterized in that a charge air box ( 22 ) by a transverse partition ( 26 ) in an inlet chamber ( 24a ) and an exit chamber ( 25a ), which in each case the charge air inlet ( 24 ) or the charge air outlet ( 25 ), that the other air box ( 23 ) formed as a deflection box and that in the transverse partition ( 26 ) a shut-off device ( 27 ) is arranged. Intercooler according to claim 20, characterized in that the obturator as a flap, in particular as a round pivoting flap ( 27 ) is formed with a central pivot axis.